r50 rob 7pol · 2020-03-12 · operating instructions remote control r50 rob 7pol 099-008782-ew501...

Operating instructions

Remote control

R50 ROB 7POL

099-008782-EW501 Observe additional system documents! 24.10.2014

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General instructions

CAUTION

Read the operating instructions!

The operating instructions provide an introduction to the safe use of the products.

• Read the operating instructions for all system components!

• Observe accident prevention regulations!

• Observe all local regulations!

• Confirm with a signature where appropriate.

NOTE

In the event of queries on installation, commissioning, operation or special conditions at the

installation site, or on usage, please contact your sales partner or our

customer service department on +49 2680 181-0.

A list of authorised sales partners can be found at www.ewm-group.com.

Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other

form of liability, regardless of type, shall be accepted. This exclusion of liability shall be deemed accepted by the

user on commissioning the equipment.

The manufacturer is unable to monitor whether or not these instructions or the conditions and methods are

observed during installation, operation, usage and maintenance of the equipment.

An incorrectly performed installation can result in material damage and injure persons as a result. For this reason,

we do not accept any responsibility or liability for losses, damages or costs arising from incorrect installation,

improper operation or incorrect usage and maintenance or any actions connected to this in any way.

© EWM AG · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany

The copyright to this document remains the property of the manufacturer.

Reprinting, including extracts, only permitted with written approval.

Subject to technical amendments.

Contents Notes on the use of these operating instructions

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1 Contents

1 Contents .................................................................................................................................................. 3

2 Safety instructions ................................................................................................................................. 5 2.1 Notes on the use of these operating instructions .......................................................................... 5 2.2 Explanation of icons ....................................................................................................................... 6 2.3 General .......................................................................................................................................... 7 2.4 Transport ........................................................................................................................................ 9 2.5 Scope of delivery ........................................................................................................................... 9

2.5.1 Ambient conditions ......................................................................................................... 9 2.5.1.1 In operation ..................................................................................................... 9 2.5.1.2 Transport and storage ..................................................................................... 9

3 Intended use ......................................................................................................................................... 10 3.1 Use and operation solely with the following machines ................................................................ 10 3.2 Documents which also apply ....................................................................................................... 11

3.2.1 Warranty ....................................................................................................................... 11 3.2.2 Declaration of Conformity ............................................................................................. 11 3.2.3 Service documents (spare parts) ................................................................................. 11

4 Machine description – quick overview .............................................................................................. 12 4.1 Front view .................................................................................................................................... 12 4.2 Rear view ..................................................................................................................................... 13 4.3 Machine control – Operating elements ........................................................................................ 14

4.3.1 Machine control – Concealed operating elements ....................................................... 16

5 Design and function ............................................................................................................................. 18 5.1 General ........................................................................................................................................ 18 5.2 Establishing the connections ....................................................................................................... 18 5.3 Gas test ........................................................................................................................................ 19 5.4 Rinse hose package function ....................................................................................................... 19

5.4.1 Setting the shielding gas quantity ................................................................................. 19 5.5 Definition of MIG/MAG welding tasks .......................................................................................... 20

5.5.1 Welding task selection .................................................................................................. 20 5.5.1.1 Operating mode ............................................................................................ 20 5.5.1.2 Choke effect / dynamics ................................................................................ 21 5.5.1.3 superPuls ...................................................................................................... 21 5.5.1.4 Burn-back ...................................................................................................... 22

5.6 MIG/MAG operating point ............................................................................................................ 23 5.6.1 Selecting the display unit .............................................................................................. 23 5.6.2 Operating point setting using material thickness .......................................................... 23

5.6.2.1 Arc length correction setting ......................................................................... 24 5.6.2.2 Accessory components for operating point setting ....................................... 24

5.7 MIG/MAG welding data display ................................................................................................... 24 5.8 coldArc / coldArc puls .................................................................................................................. 25 5.9 forceArc / forceArc puls................................................................................................................ 26 5.10 rootArc/rootArc puls ..................................................................................................................... 27 5.11 pipeSolution ................................................................................................................................. 27 5.12 MIG/MAG functional sequences / operating modes .................................................................... 28

5.12.1 Explanation of signs and functions ............................................................................... 28 5.12.2 MIG/MAG program sequence ("Program steps" mode) ............................................... 33

5.12.2.1 Selection of the program sequence parameter ............................................. 33 5.12.2.2 MIG/MAG overview of parameters ................................................................ 34 5.12.2.3 Example, tack welding (non-latched) ............................................................ 35 5.12.2.4 Example, aluminium tack welding (non-latched special) .............................. 35

5.12.3 Main program A mode .................................................................................................. 36 5.12.3.1 Selecting parameters (program A) ................................................................ 38

Contents Notes on the use of these operating instructions

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5.13 Organise welding task (JOB) ....................................................................................................... 39 5.14 Load welding task (JOB) from welding machine to remote control.............................................. 39

5.14.1 Copy welding task (JOB) from remote control to welding machine .............................. 40 5.15 Resetting JOBs (welding tasks) to the factory settings ................................................................ 42

5.15.1 Resetting a single JOB ................................................................................................. 42 5.15.2 Resetting all JOBs ........................................................................................................ 43

5.16 Special parameters (advanced settings) ...................................................................................... 44 5.16.1 Selecting, changing and saving parameters................................................................. 44

5.16.1.1 The special parameters in detail ................................................................... 45 5.16.1.2 Reset to factory settings ................................................................................ 46

5.16.2 Protective flap, welding machine control ...................................................................... 47

6 Maintenance, care and disposal ......................................................................................................... 48 6.1 General ......................................................................................................................................... 48 6.2 Maintenance work ........................................................................................................................ 48 6.3 Maintenance work, intervals......................................................................................................... 48

6.3.1 Monthly maintenance tasks .......................................................................................... 48 6.4 Disposing of equipment ................................................................................................................ 48

6.4.1 Manufacturer's declaration to the end user .................................................................. 49 6.5 Meeting the requirements of RoHS .............................................................................................. 49

7 Technical data ....................................................................................................................................... 50 7.1 R50 ROB 7POL ............................................................................................................................ 50

8 Accessories .......................................................................................................................................... 51 8.1 Connection and extension cables ................................................................................................ 51

9 Appendix A ............................................................................................................................................ 52 9.1 Overview of EWM branches......................................................................................................... 52

Safety instructions Notes on the use of these operating instructions

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2 Safety instructions 2.1 Notes on the use of these operating instructions

DANGER

Working or operating procedures which must be closely observed to prevent imminent

serious and even fatal injuries.

• Safety notes include the "DANGER" keyword in the heading with a general warning symbol.

• The hazard is also highlighted using a symbol on the edge of the page.

WARNING

Working or operating procedures which must be closely observed to prevent serious

and even fatal injuries.

• Safety notes include the "WARNING" keyword in the heading with a general warning

symbol.

• The hazard is also highlighted using a symbol in the page margin.

CAUTION

Working or operating procedures which must be closely observed to prevent possible

minor personal injury.

• The safety information includes the "CAUTION" keyword in its heading with a general

warning symbol.

• The risk is explained using a symbol on the edge of the page.

CAUTION

Working and operating procedures which must be followed precisely to avoid damaging

or destroying the product.

• The safety information includes the "CAUTION" keyword in its heading without a general

warning symbol.

• The hazard is explained using a symbol at the edge of the page.

NOTE

Special technical points which users must observe.

• Notes include the "NOTE" keyword in the heading without a general warning symbol.

Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet

points, e.g.:

• Insert the welding current lead socket into the relevant socket and lock.

Safety instructions Explanation of icons

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2.2 Explanation of icons

Symbol Description

Correct

Wrong

Press

Do not press

Turn

Switch

Switch off machine

Switch on machine

ENTERENTER

ENTER (enter the menu)

NAVIGATION

NAVIGATION (Navigating in the menu)

EXIT

EXIT (Exit the menu)

4 s

Time display (example: wait 4s/press)

Interruption in the menu display (other setting options possible)

Tool not required/do not use

Tool required/use

Safety instructions General

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2.3 General

DANGER

Electric shock!

Welding machines use high voltages which can result in potentially fatal electric shocks

and burns on contact. Even low voltages can cause you to get a shock and lead to

accidents.

• Do not touch any live parts in or on the machine!

• Connection cables and leads must be free of faults!

• Switching off alone is not sufficient!

• Place welding torch and stick electrode holder on an insulated surface!

• The unit should only be opened by specialist staff after the mains plug has been

unplugged!

• Only wear dry protective clothing!

• Wait for 4 minutes until the capacitors have discharged!

Electromagnetic fields!

The power source may cause electrical or electromagnetic fields to be produced which

could affect the correct functioning of electronic equipment such as IT or CNC devices,

telecommunication lines, power cables, signal lines and pacemakers.

• Observe the maintenance instructions - See 6 Maintenance, care and disposal chapter!

• Unwind welding leads completely!

• Shield devices or equipment sensitive to radiation accordingly!

• The correct functioning of pacemakers may be affected (obtain advice from a doctor if

necessary).

Validity of this document!

This document describes an accessory and is only valid in combination with the

operating instructions for the power source being used (welding machine)!

• Read the operating instructions, in particular the safety instructions for the power source

(welding machine)!

WARNING

Risk of accidents if these safety instructions are not observed!

Non-observance of these safety instructions is potentially fatal!

• Carefully read the safety information in this manual!

• Observe the accident prevention regulations in your country.

• Inform persons in the working area that they must observe the regulations!

Fire hazard!

Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts

and hot slag produced during the welding process.

Stray welding currents can also result in flames forming!

• Check for fire hazards in the working area!

• Do not carry any easily flammable objects such as matches or lighters.

• Keep appropriate fire extinguishing equipment to hand in the working area!

• Thoroughly remove any residue of flammable substances from the workpiece before

starting welding.

• Only continue work on welded workpieces once they have cooled down.

Do not allow to come into contact with flammable material!

• Connect welding leads correctly!

Safety instructions General

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WARNING

Risk of injury due to radiation or heat!

Arc radiation results in injury to skin and eyes.

Contact with hot workpieces and sparks results in burns.

• Use welding shield or welding helmet with the appropriate safety level (depending on the

application)!

• Wear dry protective clothing (e.g. welding shield, gloves, etc.) according to the relevant

regulations in the country in question!

• Protect persons not involved in the work against arc beams and the risk of glare using

safety curtains!

Hazards due to improper usage!

Hazards may arise for persons, animals and material objects if the equipment is not

used correctly. No liability is accepted for any damages arising from improper usage!

• The equipment must only be used in line with proper usage and by trained or expert staff!

• Do not modify or convert the equipment improperly!

CAUTION

Noise exposure!

Noise exceeding 70 dBA can cause permanent hearing damage!

• Wear suitable ear protection!

• Persons located within the working area must wear suitable ear protection!

CAUTION

Obligations of the operator!

The respective national directives and laws must be observed for operation of the

machine!

• National implementation of the framework directive (89/391/EWG), as well as the

associated individual directives.

• In particular, directive (89/655/EWG), on the minimum regulations for safety and health

protection when staff members use equipment during work.

• The regulations regarding work safety and accident prevention for the respective country.

• Setting up and operating the machine according to IEC 60974-9.

• Check at regular intervals that users are working in a safety-conscious way.

• Regular checks of the machine according to IEC 60974-4.

Damage due to the use of non-genuine parts!

The manufacturer's warranty becomes void if non-genuine parts are used!

• Only use system components and options (power sources, welding torches, electrode

holders, remote controls, spare parts and replacement parts, etc.) from our range of

products!

• Only insert and lock accessory components into the relevant connection socket when the

machine is switched off.

Trained personnel!

Commissioning is reserved for persons who have the relevant expertise of working with

arc welding machines.

Safety instructions Transport

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2.4 Transport

CAUTION

Damage due to supply lines not being disconnected!

During transport, supply lines which have not been disconnected (mains supply leads,

control leads, etc.) may cause hazards such as connected equipment tipping over and

injuring persons!

• Disconnect supply lines!

2.5 Scope of delivery The delivery is checked and packaged carefully before dispatch, however it is not possible to exclude the

possibility of damage during transit.

Receiving inspection

• Check that the delivery is complete using the delivery note!

In the event of damage to the packaging

• Check the delivery for damage (visual inspection)!

In the event of complaints

If the delivery has been damaged during transport:

• Please contact the last haulier immediately!

• Keep the packaging (for possible checking by the haulier or for the return shipment).

Packaging for returns

If possible, please use the original packaging and the original packaging material. If you have any queries

on packaging and protection during transport, please contact your supplier.

2.5.1 Ambient conditions

CAUTION

Equipment damage due to dirt accumulation!

Unusually high quantities of dust, acid, corrosive gases or substances may damage the

equipment.

• Avoid high volumes of smoke, vapour, oil vapour and grinding dust!

• Avoid ambient air containing salt (sea air)!

2.5.1.1 In operation

Temperature range of the ambient air:

• -25 °C to +40 °C

Relative air humidity:

• Up to 50% at 40 °C

• Up to 90% at 20 °C

2.5.1.2 Transport and storage

Storage in an enclosed space, temperature range of the ambient air:

• -30 °C to +70 °C

Relative air humidity

• Up to 90% at 20 °C

Intended use Use and operation solely with the following machines

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3 Intended use

WARNING

Hazards due to improper usage!

Hazards may arise for persons, animals and material objects if the equipment is not

used correctly. No liability is accepted for any damages arising from improper usage!

• The equipment must only be used in line with proper usage and by trained or expert staff!

• Do not modify or convert the equipment improperly!

3.1 Use and operation solely with the following machines • Phoenix 352, 452, 552, 1002

• alpha Q 352, 552

• Phoenix 352, 452, 552, 1002 MM

• alpha Q 352, 552 MM

Intended use Documents which also apply

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3.2 Documents which also apply 3.2.1 Warranty

NOTE

For further information, please see the accompanying supplementary sheets "Machine

and Company Data, Maintenance and Testing, Warranty"!

3.2.2 Declaration of Conformity

The designated machine conforms to EC Directives and standards in terms of its design

and construction:

• EC Low Voltage Directive (2006/95/EC),

• EC EMC Directive (2004/108/EC),

This declaration shall become null and void in the event of unauthorised modifications, improperly

conducted repairs, non-observance of the deadlines for the repetition test and / or non-permitted

conversion work not specifically authorised by the manufacturer.

The original copy of the declaration of conformity is enclosed with the unit.

3.2.3 Service documents (spare parts)

DANGER

Do not carry out any unauthorised repairs or modifications!

To avoid injury and equipment damage, the unit must only be repaired or modified by

specialist, skilled persons!

The warranty becomes null and void in the event of unauthorised interference.

• Appoint only skilled persons for repair work (trained service personnel)!

Spare parts can be obtained from the relevant authorised dealer.

Machine description – quick overview Front view

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4 Machine description – quick overview 4.1 Front view

Figure 4-1

Item Symbol Description 0

1 Lid

2 Machine control

- See 4.3 Machine control – Operating elements chapter

3 Protective cap

4 Connection socket, 7-pole (digital)

Connection to the digital remote control connection on power source or wire feed unit.

Machine description – quick overview Rear view

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4.2 Rear view

Figure 4-2


1 Holder for suspending the remote control

2 Carrying handle

3 Machine feet

4 Fixing magnet

To mount remote control on magnetisable surfaces

Machine description – quick overview Machine control – Operating elements

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4.3 Machine control – Operating elements

Figure 4-3


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1 Lid - See 4.3.1 Machine control – Concealed operating elements chapter

2

Display, left

Welding current, material thickness, wire speed, hold values

3

Push-button, parameter selection left/power-saving mode

AMP Welding current

Material thickness

Wire feed speed

Hold After welding, the values used last are shown from the main program. The

signal light is illuminated.

STBY Press for 2 s to put machine into power-saving mode.

To reactivate, activate one of the operating elements.

4

Display, JOB

Shows the currently selected welding task (JOB number).

5

Welding parameter setting, rotary dial

For setting the welding performance, for selecting the JOB (welding task) and for

setting other welding parameters.

6

Select operating mode button

Non-latched

Signal light lights up in green: Special non-latched

Signal light lights up in red: MIG spot welding

7

Display, right

Welding voltage, program number, motor current (wire feed mechanism)

8

Button, Parameter selection (right)

VOLT Welding voltage

Prog Program number

kW Welding performance display

Gas flow quantity (optional)

9

Arc length correction/selection of welding program, rotary dial

• Correction of the arc length from -9.9 V to +9.9 V.

• Selection of welding programs 0 to 15 (not possible if accessory components, such

as program torches, are connected).

10

Push-button, throttling effect (arc dynamics)

Arc is harder and more narrow

Arc is softer and wider

11

Push-button, welding type

standard MIG/MAG welding

pulsed MIG/MAG welding (not for Taurus S)


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4.3.1 Machine control – Concealed operating elements

Figure 4-4


1

Select welding parameters button

This button is used to select the welding parameters depending on the welding process

and operating mode used.

2

Signal light, gas pre-flow time

Setting range 0.0 s to 20.0 s

3 Signal light, start program (PSTART)

• Wire speed:1% to 200% of the main program PA

• Correction of the arc length -9.9 V to +9.9 V

4 sec Signal light, start time

Setting range, absolute 0.0 s to 20.0 s (0.1 s increments)

5 sec Signal light, slope time program PSTART to main program PA

Setting range 0.0 s to 20.0 s (0.1 s increments)

6 Signal light, main program (PA)

• Wire speed WF-min. to WF-max.


7 sec Signal light, duration of main program PA

Setting range 0.1 s to 20.0 s (0.1 s increments).

Used e.g. in connection with the super pulse function

8 Signal light, reduced main program (PB)



9 sec Signal light, duration reduced main program PB

Setting range 0.0 s to 20.0 s (0.1 s increments).

Used e.g. in connection with the super pulse function.

10 sec Signal light, slope time program PA (or PB) to end program PEND


11 Signal light, end program (PEND)



12 sec Signal light, duration of end program PEND


13

Signal light, gas post-flow time

Setting range 0.0 s to 20.0 s


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14 Super-

puls

Signal lamp, super pulse function

Lights up when the super pulse function is active.

15

Signal light: organising welding tasks (JOB)

Flashes when JOB number is displayed or selected

16

Press organise welding tasks (JOB) push-button

Briefly pressing the button = display of welding task selected in welding system

Holding the button down for long (> 3 s) = "Organise welding tasks (JOB)" mode:

• Load welding task (JOB) from welding machine to remote control

• Copy welding task (JOB) from remote control to welding machine

17

Push-button, wire inching/motor current (wire feed mechanism)

Drahtelektrode einfädeln

18

Gas test / rinse button

• Gas test: For setting the shielding gas quantity

• Rinse: For rinsing longer hose packages

Schutzgasversorgung

Design and function General

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5 Design and function 5.1 General

NOTE

Basically, all descriptions on the process settings in the standard operating

instructions shall apply. This operating manual exclusively describes deviating control

functions.

5.2 Establishing the connections

CAUTION

Damage to the machine due to improper connection!

The remote controls have been developed to be connected to welding machines or wire

feed units only. Connecting them to other machines may cause damage to the

machines!

• Observe the operating instructions for the welding machine or wire feed unit!

• Switch off the welding machine before connecting!

NOTE

Observe documentation of other system components when connecting!

• Switch off the welding machine

• Insert the male connector plug (socket) into the remote control connection socket and lock by turning

to the right.

• Insert the male connector plug (pin) into the remote control connection socket of the welding machine

and lock by turning to the right.

Design and function Gas test

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5.3 Gas test • Slowly open the gas cylinder valve.

• Open the pressure regulator.

• Switch on the power source at the main switch.

• Initiate gas test function on the machine control.

• Set the relevant gas quantity for the application on the pressure regulator.

• The gas test is triggered on the machine control by pressing the button briefly.

Shielding gas flows for around 25 seconds or until the button is pressed again.

5.4 Rinse hose package function Operating

Element

Action Result

5 s

Select rinse hose package.

Shielding gas flows continuously until the Gas Test button is pressed

again.

5.4.1 Setting the shielding gas quantity Welding process Recommended shielding gas quantity

MAG welding Wire diameter x 11.5 = l/min

MIG brazing Wire diameter x 11.5 = l/min

MIG welding (aluminium) Wire diameter x 13.5 = l/min (100 % argon)

TIG Gas nozzle diameter in mm corresponds to l/min gas throughput

Helium-rich gas mixtures require a higher gas volume!

The table below can be used to correct the gas volume calculated where necessary:

Shielding gas Factor

75% Ar/25% He 1.14

50% Ar/50% He 1.35

25% Ar/75% He 1.75

100% He 3.16

NOTE

Incorrect shielding gas setting!

If the shielding gas setting is too low or too high, this can introduce air to the weld pool

and may cause pores to form.

• Adjust the shielding gas quantity to suit the welding task!

Design and function Definition of MIG/MAG welding tasks

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5.5 Definition of MIG/MAG welding tasks

NOTE

Please note the relevant documentation of the accessory components.

This range of machines feature simple operation with a very wide range of functions.

• Various JOBs (i.e. welding tasks consisting of welding process, material type, wire diameter and

shielding gas type) have been pre-defined JOB-List.

• Simple JOB selection from a list of pre-defined JOBs (sticker on the machine).

• The required process parameters are calculated by the system depending on the operating point

specified (single-dial operation via wire speed rotary dial).

• Additional parameters can be modified as required in the configuration menu on the control or using

the PC300.NET welding parameter software.

5.5.1 Welding task selection Operating

element

Action Result Display

1 x

JOB list selection (signal light flashes)

Set JOB number.

Wait 3 s until the setting has been applied.

5.5.1.1 Operating mode

Operating

element


n x

Select operating mode

The LED displays the selected operating mode.

Non-latched operation

Latched operation

Green Special non-latched mode

Red Spot operating mode

Special latched mode

No change


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5.5.1.2 Choke effect / dynamics

EXITENTER

3 s

Figure 5-1

Display Setting/selection

Dynamics setting

40: Arc harder and narrower

-40: Arc softer and wider

5.5.1.3 superPuls

In superPuls mode, the program toggles from main program (PA) to reduced main program (PB). This

function is used e.g. in thin sheet welding to accurately reduce the heat input or weld vertical-up welds

without weaving. superPuls in combination with EWM welding processes offers many possibilities.

Welding performance can be represented as average value (ex works) or solely as program A value. If

the average value display is activated the signal lights of the main (PA) and reduced main program (PB)

are illuminated simultaneously. The display variants can be changed using special parameter P19, see

chapter "Special parameters (Advanced settings)".

EXITENTER

3 s

Figure 5-2


Selects super pulses

Switches function on or off.

Switch on

Switching on machine function

Switch off

Switching off machine function


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5.5.1.4 Burn-back

ENTER

3 s

EXIT

3 s

Figure 5-3


menu burn back

Set burn back

Parameter setting (setting range 0 to 499)

Back-burn set too high: large drops developing on the wire electrode result in poor

ignition properties or the wire electrode sticking to the welding nozzle.

Back-burn set too low: Wire electrode sticks in the molten pool

Design and function MIG/MAG operating point

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5.6 MIG/MAG operating point The operating point (welding output) is specified using the principle of MIG/MAG one-dial operation, i.e.

the user need only specify the operating point by setting the required wire speed, for example, and the

digital system will calculate the optimum values for welding current and voltage (operating point).

The operating point setting can also be specified using the accessory components such as the remote

control, welding torch, etc.

5.6.1 Selecting the display unit

Figure 5-4

The operating point (welding performance) can be displayed as the welding current, material thickness or

wire speed.

Operating

element

Action Result

n x

Switching the display between:

Welding current

Material thickness

Wire speed

Application example

Aluminium is to be welded.

• Material = AlMg,

• Gas = Ar 100%,

• Wire diameter = 1.2 mm

The correct wire speed is not known and is to be determined.

• Select the appropriate JOB (see "JOB list" sticker)

• Switch to the material thickness display

• Set the material thickness as appropriate (e.g. 5 mm)

• Switch to the wire speed display

The resulting wire speed will be shown (e.g. 8.4 m/min).

5.6.2 Operating point setting using material thickness Given below is a description of the setting work via the wire speed parameters as an example of

operating point setting.

Operating

element


Increase or reduce welding performance via the

wire speed parameter.

Display example: 10.5 m/min

Design and function MIG/MAG welding data display

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5.6.2.1 Arc length correction setting

The arc length can be corrected as follows.

Operating

element


"Arc length correction" setting

(Display example: -0.9V,

setting range -9.9 V to +9.9 V)

5.6.2.2 Accessory components for operating point setting

The operating point can also be set with various accessory components such as

• remote controls

• special torches

• PC software

• robot and industrial bus interfaces (optional mechanised welding interface required – not possible for

all machines in this series!)

You will find an overview of accessory components in the "Accessories" chapter. See the operating

instructions for the machine in question for a more detailed description of the individual machines and

their functions.

5.7 MIG/MAG welding data display To the left and right of the control displays are the "Parameter selection" buttons ( ). They are used to

select welding parameters to be displayed.

Each press of the button advances the display to the next parameter (LEDs next to the button indicate the

selection). After the last parameter is reached, the system starts again from the beginning.

Figure 5-5

The display shows:

• Nominal values (before welding)

• Actual values (during welding)

• Hold values (after welding)

Parameter Nominal values Actual values Hold values

Welding current

Material thickness

Wire feed speed

Welding voltage

Welding performance

When settings are changed (e.g. wire feed speed) the display immediately switches to nominal

value setting.

Design and function coldArc / coldArc puls

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5.8 coldArc / coldArc puls Heat-reduced, low-spatter short arc for welding and brazing of thin metal sheets with low distortion and

for root welding with excellent gap bridging properties.

Figure 5-6

After selecting the coldArc process - See 5.5.1 Welding task selection chapter the following properties are

available:

• Less distortion and reduced discolouration thanks to minimised heat input

• Considerably reduced spatter thanks to virtually power-free material transfer

• Easy welding of root passes in all panel thicknesses and in all positions

• Perfect gap bridging even with inconsistent gap widths

• Unalloyed, low-alloy and high-alloy steels and also dissimilar joints of even the thinnest metal sheets

• Brazing of CrNi sheets with CuAl8/AlBz8

• Brazing and welding of coated metal sheets, e.g. with CuSi, AlSi and Zn

• Manual and automated applications

coldArc welding to: Wire Ø (mm)

0.8 0.9 1 1.2 1.6

Material Gas JOB JOB JOB JOB JOB

CrNi Ar 91–99% - - - - 51 7.0 52 6.0 - -

AlMg Ar 100% - - - - 55 8.0 56 8.0 - -

ALSi Ar 100% - - - - 59 8.0 60 6.0 - -

AL99 Ar 100% - - - - 63 8.0 64 6.0 - -

Steel

Ar 91–99% - - - - - - - - - -

Ar 80–90% 191 7.0 192 6.0 193 6.0 194 5.0 195 5.0

CO2 182 7.0 183 6.0 184 6.0 185 5.0 186 5.0

coldArc brazing to: Wire Ø (mm)

0.6 0.8 0.9 1 1.2 1.6

Material Gas JOB JOB JOB JOB JOB JOB

CuSi Ar 100% - - 66 10.0 - - 67 8.0 68 6.0 69 6.0

CuAl Ar 100% - - 70 7.0 - - 71 6.0 72 6.0 73 7.0

AlSi Ar 100% - - 196 8.0 - - 197 8.0 198 8.0 199 8.0

Zn Ar 100% - - 200 6.0 - - 201 6.0 202 6.0 203 6.0

You can make use of these properties after selecting the coldArc process (see the "Selecting a MIG/MAG

welding task" chapter).

With coldArc welding, it is important to ensure good quality wire feeding because of the welding

filler materials being used!

• Equip the welding torch and torch hose package to suit the task! (siehe Kapitel Anschluss

Schweißbrenner and the operating instructions for the welding torch.)

NOTE

This function can only be enabled with the PC300.NET software.

• (See operating instructions for the software)

Design and function forceArc / forceArc puls

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5.9 forceArc / forceArc puls Heat-reduced, directionally stable and powerful arc with deep penetration for the upper power range.

Figure 5-7

• Smaller included angle due to deep penetration and directionally stable arc

• Excellent root and sidewall fusion

• Secure welding also with very long stick-outs

• Reduced undercuts

• Un-, low- and high-alloyed steels as well as high-tensile fine-grained building steels


forceArc welding from: Wire Ø (mm)

0.8 1 1.2 1.6

Material Gas JOB JOB JOB JOB

Steel Ar 91–99% 190 17.0 254 12.0 255 9.5 256 7.0

Ar 80–90% 189 17.0 179 12.0 180 9.5 181 6.0

CrNi Ar 91–99% - - 251 12.0 252 12.0 253 6.0

You can make use of these properties after selecting the forceArc process "- See 5.5.1 Welding task

selection chapter".

As with pulse arc welding, it is important to make sure of a good welding current connection.

• Keep welding current cables as short as possible and ensure that cable cross-sections are adequate!

• Fully unroll welding current cables, torche hose packages and, if applicable, intermediate hose

packages. Avoid loops!

• Use welding torches, preferably water-cooled, that are suitable for the higher power range.

• Use welding wire with adequate copper coating when welding steel. The wire spool should have layer

spooling.

NOTE

Unstable arc!

Welding current cables that are not fully unrolled can cause faults in the arc (flickering).

• Fully unroll welding current cables, torch hose packages and, if applicable, intermediate

hose packages. Avoid loops!

Design and function rootArc/rootArc puls

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5.10 rootArc/rootArc puls Short arc with easy weld modelling capabilities for effortless gap bridging and positional welding.

Figure 5-8

• Reduced spatter compared to standard short arc

• Good root formation and secure sidewall fusion

• Un-alloyed and low-alloy steels


rootArc welding up to: Wire Ø (mm)

0.6 0.8 0.9 1 1.2 1.6


Steel CO2 - - - - - - 204 7.0 205 5.0 - -

Ar 80–90% - - - - - - 206 8.0 207 6.0 - -

NOTE

Unstable arc!

Welding current cables that are not fully unrolled can cause faults in the arc (flickering).

• Fully unroll welding current cables, torch hose packages and, if applicable, intermediate

hose packages. Avoid loops!

5.11 pipeSolution Powerful arc for rapid, secure welding with and without gap in all positions.

Figure 5-9

• Root welding for metal sheets and pipes in all positions

• Unalloyed and low-alloy steels as well as high-tensile fine-grained steels


pipeSolution welding to: Wire Ø (mm)

0.6 0.8 0.9 1 1.2 1.6


Steel CO2 x x x x x x 171 6.0 172 5.0 x x

Ar 80–90% x x x x x x 173 6.0 174 5.0 x x

Design and function MIG/MAG functional sequences / operating modes

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5.12 MIG/MAG functional sequences / operating modes

NOTE

There are optimum pre-sets for welding parameters such as gas pre-flow and burn

back, etc. for numerous applications (although these can also be changed if required).

5.12.1 Explanation of signs and functions Symbol Meaning

Start of welding

End of welding

Shielding gas flowing

I Welding output

Wire electrode is being conveyed

Wire creep

Wire burn-back

Gas pre-flows

Gas post-flows

Non-latched

Non-latched special

t Time

PSTART Start program

Flat Main program

PEND End program


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Non-latched mode

Figure 5-10

Step 1

• Robot issues the start signal to the power source.

• Shielding gas is expelled (gas pre-flows).

• Wire feed motor runs at “creep speed”.

• Arc ignites after the wire electrode makes contact with the workpiece; welding current flows.

• Changeover to pre-selected wire speed (main program PA).

Step 2

• Robot issues the stop signal to the power source.

• WF motor stops.

• Arc is extinguished after the pre-selected wire burn-back time elapses.

• Gas post-flow time elapses.


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Non-latched operation with superpulse

Figure 5-11

Step 1


• Shielding gas is expelled (gas pre-flows).


• Arc ignites after the wire electrode makes contact with the workpiece; welding current flows.

• Start the super pulse function beginning with main program PA:

The welding parameters switch between main program PA and the reduced main program PB at the

specified times.

Step 2


• Super pulse function is ended.

• Wire feed motor stops.

• Arc is extinguished after the pre-selected wire burn-back time elapses. • Gas post-flow time elapses.


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Special, non-latched

Figure 5-12

Step 1


• Shielding gas is expelled (gas pre-flows)


• Arc ignites after the wire electrode makes contact with the workpiece, welding current is flowing (start

program PSTART for the time tstart).

• Slope to main program PA.

Step 2


• Slope to end program PEND for the time tend.

• WF motor stops.




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Special, non-latched with superpulse

Figure 5-13

Step 1


• Shielding gas is expelled (gas pre-flows)


• Arc ignites after the wire electrode makes contact with the workpiece, welding current is flowing (start

program PSTART for the time tstart).

• Slope on main program PA.

• Start the super pulse function beginning with main program PA:

The welding parameters switch between main program PA and the reduced main program PB at the

specified times.

Step 2


• Super pulse function is ended.

• Slope to end program PEND for the time tend.

• WF motor stops.




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5.12.2 MIG/MAG program sequence ("Program steps" mode) Certain materials, such as aluminium, require special functions in order to be able to weld them safely

and at high quality. The latched special operating mode is used here with the following programs:

• Start program PSTART (reduction of cool points at the start of the seam)

• Main program PA (continuous welding)

• Reduced main program PB (targeted heat reduction)

• End program PEND) (minimisation of end craters via targeted heat reduction)

The programs include the parameters wire speed (operating point), arc length correction, slope times,

program duration, etc.

Figure 5-14

In every JOB, separate settings can be made for the ignition program, reduced main program and end

program as to whether or not to alternate with the pulse process.

These properties are stored on the welding machine with the JOB. This means that in the factory settings,

the pulse process is active during the end program in all forceArc JOBs.

NOTE

This function can only be enabled with the PC300.NET software.

• (See operating instructions for the software)

5.12.2.1 Selection of the program sequence parameter

Operating

Element


n x

Select parameter in the program sequence

Setting welding parameters


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5.12.2.2 MIG/MAG overview of parameters

NOTE

PSTART, PB, and PEND are set as relative programs ex faxtory. They relate to percentages

of the wire feed value of the main program PA. These programs can also be set in an

absolute manner, if desired (see Setting of special parameter P21).

Figure 5-15

Basic Parameters

Item Meaning / Explanation Setting Range

1 1 Gas pre-flow time 0.0s to 20.0s

2 2 PSTART

Wire speed, relative

Arc length correction

1% to 200%

-9.9V to +9.9V

3 3 Duration 0.0s to 20.0s

4 4 Slope duration from PSTART to PA 0.0s to 20.0s

5 5 PA

Wire speed, absolute

0.1 m/min to 40 m/min

6 7 Duration (spot time and superpulse) 0.01s to 20.0s

7 8 PB


Arc length correction, relative

1% to 200%

-9.9V to +9.9V

8 9 Duration 0.01s to 20.0s

9 1

0

Slope duration from PA to PEND 0.0s to 20s

10 1

1

PEND


Arc length correction

1% to 200%

-9.9V to +9.9V

11 1

2

Duration (superpulse) 0.0s to 20s

12 1

3

Gas post-flow time 0.0s to 20s

13 1

4

Superpulses On / Off


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5.12.2.3 Example, tack welding (non-latched)

Figure 5-16

Basic parameters

Parameter Meaning / explanation Setting range

GASstr Gas pre-flow time 0.0s to 20.0s

GASend: Gas post-flow time 0.0s to 20s

RUECK Wire burn-back length 2 to 500

"PA" main program

Parameter Meaning / explanation Setting range

Setting the wire speed

5.12.2.4 Example, aluminium tack welding (non-latched special)

Figure 5-17

Basic parameters

Welding parameter Meaning / explanation Setting range

GASstr Gas pre-flow time 0.0s to 20.0s

GASend: Gas post-flow time 0.0s to 20.0s

RUECK Wire burn-back length 2 to 500

"PSTART" start program


DVstart Wire speed 0% to 200%

Ustart Arc length correction -9.9V to +9.9V

tstart Duration 0.0s to 20s

"PA" main program


Setting the wire speed

"PEND" end-crater program


DVend Wire speed 0% to 200%

Uend Arc length correction -9.9V to +9.9V

tend Duration 0.0s to 20s


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5.12.3 Main program A mode Different welding tasks or positions on a workpiece demand various welding performances (operating

points) or welding programs. The following parameters are stored in each of the up to 16 programs:

• Operating mode

• Welding type

• Superpulses (ON/OFF)

• Wire feed speed (DV2)

• Voltage correction (U2)

• Dynamics (DYN2)

The user can change the main program welding parameters using the following components.

P

rog

ram

sw

itch

ing

JO

B s

wit

ch

ing

Pro

gra

m

Op

era

tin

g m

od

e

su

perP

uls

Wir

e f

eed

sp

eed

Vo

ltag

e

co

rre

cti

on

Dyn

am

ics

RC panel

Welding power source

control:

No Yes P0

No Yes Yes Yes Yes P1...15

R50 ROB

Remote control Yes Yes P0

Yes P1...15

PC 300.NET

Software No P0 Yes No

P1...15 Yes


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Example 1: Welding workpieces with different sheet metal thicknesses (non-latched)

Figure 5-18

Example 2: Welding different positions on a workpiece (latched)

Figure 5-19

Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched

special)

Figure 5-20

NOTE

Up to 16 programs (PA0 to PA15) can be defined.

An operating point (wire speed, arc length correction, dynamics/choke effect) can be defined

permanently in each program.

Program P0 is an exception: the settings for operating points are made manually here.

Changes to the welding parameters are saved immediately!


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5.12.3.1 Selecting parameters (program A)

NOTE

You can only change the welding parameters if a key switch is installed in the welding

system and is turned to position 1.

Operating

element


n x

Change welding data display over to program

display.

(LED Prog is on)

Select program number.

Display example: Program "1".

n x

Select program sequence parameter

"Main program (PA)".

(LED is on)

Set wire speed.

(Absolute value)

Set arc length correction.

Display example: "-0.8 V" correction

(Setting range: -9.9 V to +9.9 V)

1 x

Select "Dynamic" program sequence parameter.

Set dynamic. (Setting range 40 to -40)

40: Arc hard and narrow.

-40: Arc soft and wide.

Design and function Organise welding task (JOB)

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5.13 Organise welding task (JOB) The remote control is equipped with a data storage medium (Flash ROM). Users can download any

welding task (JOB) onto this memory from the memory of the welding machine. This JOB can

subsequently be copied via an existing JOB in the free memory of the welding machine (JOB 129 -

JOB 169) or onto itself. Likewise, it is also possible to copy this JOB to other welding systems that have

been approved for this remote control. The unit will once again return to the main menu if the user does

not make any entry within 10 seconds.

5.14 Load welding task (JOB) from welding machine to remote control

3 s

3 s

1

3

4

5

2

Figure 5-21


1

Press organise welding tasks (JOB) push-button for at least 3 sec

The remote control switches to the "Organise welding tasks (JOB)" mode.

2

Select function:

Load welding task (JOB).

3

JOB selection

Select any JOB for loading.

4


JOB is loaded into remote control memory.

5 JOB will be loaded

The system returns to the main menu following completion of the loading process.

Design and function Load welding task (JOB) from welding machine to remote control

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5.14.1 Copy welding task (JOB) from remote control to welding machine

NOTE

A JOB must first be loaded onto the remote control before it can be copied (also see

chapter "Loading the welding task (JOB) from the welding machine to the remote

control"). The loaded JOB can subsequently be copied onto itself or to a storage

location in the free space of the power source (JOB 129 - JOB 169).

3 s

3 s

3

4

5

6

7

2

1

Figure 5-22

Design and function Load welding task (JOB) from welding machine to remote control

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1



2

Select function:

Copy welding task (JOB)

3 Display of JOB saved in the remote control

Example: JOB 129

4

Press organise welding tasks (JOB) push-button

The remote control switches to the target selection of the JOB to be overwritten in the

welding machine.

5

Selection of the JOB to be overwritten in the welding machine

The JOB loaded in the remote control memory can be copied via an existing JOB in the

free memory of the welding machine (JOB 129 - JOB 169) or onto itself.

6


The copy process is started.

7 JOB is being copied

Following completion of the copying process, the program returns to the main menu.

Design and function Resetting JOBs (welding tasks) to the factory settings

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5.15 Resetting JOBs (welding tasks) to the factory settings

NOTE

All customised welding parameters that are stored will be replaced by the factory

settings.

5.15.1 Resetting a single JOB

3 s

3 s

1

3

4

5

2

Figure 5-23


1



2

Select function:

Reset welding task (JOB).

3

JOB selection

Select any JOB for loading.

4

Press the "organise welding tasks (JOB)" push-button for at least 3 sec.

The JOB will be reset to the factory settings.

5 JOB will be reset.


Design and function Resetting JOBs (welding tasks) to the factory settings

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5.15.2 Resetting all JOBs

NOTE

JOBs 1–128 and 170–256 will be reset.

Custom JOBs 129–169 are maintained.

3 s

3 s

1

3

4

5

2

Figure 5-24


1



2

Select function:

Reset welding task (JOB).

3

Parameter selection

Select parameter rES ALL for the process.

4

Press the "organise welding tasks (JOB)" push-button for at least 3 sec.

The JOB will be reset to the factory settings.

5 All JOBs will be reset.


Design and function Special parameters (advanced settings)

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5.16 Special parameters (advanced settings) Special parameters (P1 to Pn) are applied for customer-specific configuration of machine functions. This

allows the user maximum flexibility in optimising their requirements.

These settings are not configured directly on the machine control since a regular setting of the

parameters is generally not required. The number of selectable special parameters can deviate between

the machine controls used in the welding system (also see the relevant standard operating instructions).

If required, the special parameters can be reset to the factory settings.

5.16.1 Selecting, changing and saving parameters

NOTE

ENTER (Enter the menu)

• Switch off the machine at the main switch.

• Press and hold the "left parameter selection" button on the remote control and, at the same

time, switch on the machine.

NAVIGATION (Navigate the menu)

• Select parameters by turning the "welding parameter setting" rotary dial.

• Set or change parameters by turning the "arc length correction/select welding program"

rotary dial.

EXIT (Exit the menu)

• Press the "right parameter selection" button (switch machine off and on again).

ENTER

+

EXIT

NAVIGATION

l

0

Figure 5-25


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Block program "0"

0 = P0 enabled (Ex works)

1 = P0 blocked

Program limitation

Programs 1 to max. 15

Ex works: 15

HOLD function

0 = HOLD values are not displayed

1 = HOLD values are displayed (Ex works)

Mean value display for super pulses

0 = Function switched off

1 = Function switched on (factory setting)

5.16.1.1 The special parameters in detail

Program "0", releasing the program block (P2)

The program P0 (manual setting) is blocked. Only operation with P1-P15 is possible, irrespective of the

key switch position.

Program limit (P4)

Program selection can be limited with special parameter P4.

• The setting is adopted for all JOBs.

• Program selection depends on the position of the "welding torch function" changeover switch (see

"Machine description"). Programs can only be switched when the changeover switch is in the

"Program" position.

• Programs can be switched by means of a connected remote control or special welding torch.

• It is only possible to switch programs by means of the "arc length correction/select welding program"

rotary dial (see "Machine description") if no special welding torch is connected.

Hold function (P15)

Hold function active (P15 = 1)

• Mean values for the last main program parameters used for welding are displayed.

Hold function not active (P15 = 0)

• Setpoint values for the main program parameters are displayed.

Mean value display for super pulses (P19)

Function active (P19 = 1)

• For super pulses, the mean power from program A (PA) and program B (PB) is shown in the display

(factory setting).

Function inactive (P19 = 0)

• Only power from program A is displayed for super pulses.


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5.16.1.2 Reset to factory settings

NOTE

All special parameters will be overwritten by the factory settings!

The welding task (JOB) will be deleted in the remote control memory.

Operating

element


left right

Switch off the welding machine -

Press and hold the "right parameter selection"

push-button on remote control -

Switch on the welding machine

Release push-button

Wait for about 3 seconds

Switch off the welding machine and restart in

order to implement the changes -


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5.16.2 Protective flap, welding machine control

Figure 5-26


1 Protective cap

2 Lid

3 Bracket, protective cap

• Push the right-hand bracket of the protective cap to the right and remove the protective cap.

Maintenance, care and disposal General

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6 Maintenance, care and disposal 6.1 General

When used in the specified environmental conditions and under normal operating conditions, this

machine is largely maintenance-free and requires a minimum of care.

There are some points, which should be observed, to guarantee fault-free operation of your welding

machine. Among these are regular cleaning and checking as described below, depending on the pollution

level of the environment and the length of time the unit is in use.

6.2 Maintenance work

DANGER

Do not carry out any unauthorised repairs or modifications!

To avoid injury and equipment damage, the unit must only be repaired or modified by

specialist, skilled persons!

The warranty becomes null and void in the event of unauthorised interference.

• Appoint only skilled persons for repair work (trained service personnel)!

Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the

right to claim under warranty is void. In all service matters, always consult the dealer who supplied the

machine. Return deliveries of defective equipment subject to warranty may only be made through your

dealer. When replacing parts, use only original spare parts. When ordering spare parts, please quote the

machine type, serial number and item number of the machine, as well as the type designation and item

number of the spare part.

6.3 Maintenance work, intervals 6.3.1 Monthly maintenance tasks

• Check control leads and their strain relief for damage.

• Carry out functional test of operating, signalling, safety and/or adjustment devices.

• Other, general condition

6.4 Disposing of equipment

NOTE

Proper disposal!

The machine contains valuable raw materials, which should be recycled, and

electronic components, which must be disposed of.

• Do not dispose of in household waste!

• Observe the local regulations regarding disposal!

Maintenance, care and disposal Meeting the requirements of RoHS

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6.4.1 Manufacturer's declaration to the end user • According to European provisions (guideline 2002/96/EG of the European Parliament and the Council

of January, 27th 2003), used electric and electronic equipment may no longer be placed in unsorted

municipal waste. It must be collected separately. The symbol depicting a waste container on wheels

indicates that the equipment must be collected separately.

This machine is to be placed for disposal or recycling in the waste separation systems provided for

this purpose.

• According to German law (law governing the distribution, taking back and environmentally correct

disposal of electric and electronic equipment (ElektroG) from 16.03.2005), used machines are to be

placed in a collection system separate from unsorted municipal waste. The public waste management

utilities (communities) have created collection points at which used equipment from private

households can be disposed of free of charge.

• Information about giving back used equipment or about collections can be obtained from the

respective municipal administration office.

• EWM participates in an approved waste disposal and recycling system and is registered in the Used

Electrical Equipment Register (EAR) under number WEEE DE 57686922.

• In addition to this, returns are also possible throughout Europe via EWM sales partners.

6.5 Meeting the requirements of RoHS We, EWM AG Mündersbach, hereby confirm that all products supplied by us which are affected by the

RoHS Directive, meet the requirements of the RoHS (Directive 2002/95/EC).

Technical data R50 ROB 7POL

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7 Technical data

NOTE

Performance specifications and guarantee only in connection with original spare and

replacement parts!

7.1 R50 ROB 7POL Interface 7-pole

Dimensions L x W x

H

115 x 235 x 300 mm

Weight 3.2 kg

Accessories Connection and extension cables

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8 Accessories 8.1 Connection and extension cables

Type Designation Item no.

FRV 7POL 10 m Extension/connecting cable 092-000201-00000




Appendix A Overview of EWM branches

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9 Appendix A 9.1 Overview of EWM branches